U.S. patent application number 16/345270 was filed with the patent office on 2019-09-26 for rare earth permanent magnet and rare earth permanent magnet manufacturing method.
This patent application is currently assigned to IHI Corporation. The applicant listed for this patent is IHI Corporation. Invention is credited to Hidekazu BANNO, Haruki EGUCHI, Keisuke NAGAO, Isao NAKANOWATARI, Nausuki YONEYAMA.
Application Number | 20190295753 16/345270 |
Document ID | / |
Family ID | 62023629 |
Filed Date | 2019-09-26 |
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United States Patent
Application |
20190295753 |
Kind Code |
A1 |
YONEYAMA; Nausuki ; et
al. |
September 26, 2019 |
RARE EARTH PERMANENT MAGNET AND RARE EARTH PERMANENT MAGNET
MANUFACTURING METHOD
Abstract
A rare earth permanent magnet includes a main phase containing:
a rare earth element R of one or more types including Nd; an
element L of one or more types selected from a group consisting of
Co, Be, Li, Al, and Si; B; and Fe, wherein crystals which form the
main phase belong to P4.sub.2/mnm; some of B atoms occupying a 4f
site of the crystals are substituted with atoms of the element L;
each distribution of Nd atoms and the atoms of the element L
appears along a C-axis direction of the crystals in a plurality of
cycles; and the rare earth permanent magnet includes an area where
a cycle of the atoms of the element L matches a cycle of the Nd
atoms.
Inventors: |
YONEYAMA; Nausuki; (Tokyo,
JP) ; EGUCHI; Haruki; (Tokyo, JP) ; BANNO;
Hidekazu; (Tokyo, JP) ; NAKANOWATARI; Isao;
(Tokyo, JP) ; NAGAO; Keisuke; (Tokyo, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
IHI Corporation |
Tokyo |
|
JP |
|
|
Assignee: |
IHI Corporation
Tokyo
JP
|
Family ID: |
62023629 |
Appl. No.: |
16/345270 |
Filed: |
October 27, 2017 |
PCT Filed: |
October 27, 2017 |
PCT NO: |
PCT/JP2017/039015 |
371 Date: |
April 26, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22F 2301/355 20130101;
C22C 38/005 20130101; H01F 1/057 20130101; H01F 41/02 20130101;
H01F 41/0266 20130101; C22C 38/00 20130101; B22F 3/00 20130101;
H01F 1/0577 20130101; B22F 2003/248 20130101; B22F 3/10 20130101;
B22F 1/00 20130101; C22C 2202/02 20130101; B22F 3/24 20130101; C21D
6/00 20130101 |
International
Class: |
H01F 1/057 20060101
H01F001/057; H01F 41/02 20060101 H01F041/02; C22C 38/00 20060101
C22C038/00; B22F 3/10 20060101 B22F003/10; B22F 3/24 20060101
B22F003/24 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 28, 2016 |
JP |
2016-212359 |
Claims
1. A rare earth permanent magnet comprising a main phase
containing: a rare earth element R of one or more types including
Nd; an element L of one or more types selected from a group
consisting of Co, Be, Li, Al, and Si; B (boron); and Fe (iron),
wherein crystals which form the main phase belong to P4.sub.2/mnm;
some of B atoms occupying a 4f site of the crystals are substituted
with atoms of the element L; each distribution of Nd atoms and the
atoms of the element L appears along a C-axis direction of the
crystals in a plurality of cycles; and the rare earth permanent
magnet includes an area where a cycle of the atoms of the element L
matches a cycle of the Nd atoms.
2. The rare earth permanent magnet according to claim 1, wherein 15
or more cycles of the atoms of the element L successively match 15
or more cycles of the Nd atoms.
3. The rare earth permanent magnet according to claim 1, wherein a
distance of the C-axis direction of the crystals in the area where
the cycle of the atoms of the element L matches the cycle of the Nd
atoms is 7 nm or more.
4. The rare earth permanent magnet according to claim 1, wherein
some of atoms of one or more types selected from a group consisting
of Nd atoms occupying the 4f site of the crystals belonging to
P4.sub.2/mnm and Fe atoms occupying an 8j site are substituted with
the atoms of the element L.
5. The rare earth permanent magnet according to claim 1, wherein
the main phase contains an element A of one or more types selected
from a group consisting of Tb, Sm, Gd, Ho, and Er.
6. A rare earth permanent magnet manufacturing method comprising: a
degreasing step of retaining, in vacuum, a green compact of a raw
material alloy containing a rare earth element R of one or more
types including Nd, an element of one or more types selected from a
group consisting of Co, Be, Li, Al, Si, Cu, Nb, Zr, Ti, and Ga, B,
and Fe; and a carbon reduction step of reducing a carbon content in
the green compact before the degreasing step.
7. The rare earth permanent magnet manufacturing method according
to claim 6, wherein the carbon reduction step includes a degassing
step of retaining the green compact at a temperature of 100.degree.
C. or lower for one hour or longer before the degreasing step.
8. The rare earth permanent magnet manufacturing method according
to claim 6, wherein the carbon reduction step includes a drying
step of retaining the green compact in an atmosphere of a dew point
of -60.degree. C. or lower before the degreasing step.
9. The rare earth permanent magnet manufacturing method according
to claim 8, wherein the drying step is executed after the degassing
step.
10. The rare earth permanent magnet manufacturing method according
to claim 6, further comprising: a sintering step of sintering the
green compact after the degreasing step; and a heat treatment step
of applying a heat treatment to a sintered compact produced in the
sintering step at a temperature lower than a sintering temperature.
Description
TECHNICAL FIELD
[0001] The present disclosure relates to a rare earth permanent
magnet containing a rare earth element (R), boron (B), and iron
(Fe).
BACKGROUND ART
[0002] There are high demands for rare earth permanent magnets for
the purposes of uses in automobiles, machine tools, wind power
generators, and so on. Furthermore, technological developments
relating to achievement of high performance, downsizing, and energy
saving are required in order to optimize the rare earth permanent
magnets for the respective uses. In order to satisfy these
requirements, it is proposed to control fine structures by
adjusting compositions of raw materials and manufacturing
methods.
[0003] PTL 1 discloses a rare earth magnet mainly composed of R
(where R is an element of one or more types selected from rare
earth elements including Y and includes Nd as an essential
component), B, Al, Cu, Zr, Co, O, C, and Fe, wherein content rates
of the respective elements are as follows: 25 to 34 mass % of R,
0.87 to 0.94 mass % of B, 0.03 to 0.3 mass % of Al, 0.03 to 0.11
mass % of Cu, 0.03 to 0.25 mass % of Zr, 3 mass % or less of Co
(excluding 0 mass %), 0.03 to 0.1 mass % of 0, 0.03 to 0.15 mass %
of C, and the remainder of Fe.
[0004] However, factors that achieves the high performance of the
rare earth permanent magnets have not been completely elucidated.
Therefore, discussions about the means for enhancing magnetic
performance have been continuing and such discussions and trials
and errors are expected to provide a rare earth permanent magnet
which exhibits further excellent performance.
CITATION LIST
Patent Literature
[0005] PTL 1: Japanese Patent Application Laid-Open (Kokai)
Publication No. 2013-70062
SUMMARY OF THE DISCLOSURE
Problems to be Solved
[0006] It is an object of the present disclosure to provide a rare
earth permanent magnet that exhibits high magnetic performance.
Means to Solve the Problems
[0007] An aspect of the present disclosure is a rare earth
permanent magnet including a main phase containing: a rare earth
element R of one or more types including Nd (neodymium); an element
L of one or more types selected from a group consisting of Co
(cobalt), Be (beryllium), Li (lithium), Al (aluminum), and Si
(silicon); B (boron); and Fe (iron), wherein crystals which form
the main phase belong to P4.sub.2/mnm; some of B atoms occupying a
4f site of the crystals are substituted with atoms of the element
L; each distribution of Nd atoms and the atoms of the element L
appears along a C-axis direction of the crystals with periodic
structure in a plurality of cycles; and the rare earth permanent
magnet includes an area where a cycle of the atoms of the element L
matches a cycle of the Nd atoms.
Effects of the Disclosure
[0008] The present disclosure can provide the rare earth permanent
magnet which exhibits the high magnetic performance.
BRIEF DESCRIPTION OF DRAWINGS
[0009] FIG. 1 is element analysis results of examples of the
present disclosure;
[0010] FIG. 2 is diagrams illustrating an element analysis result
of an example of the present disclosure and a structural model of
crystals which form a main phase of the present disclosure;
[0011] FIG. 3 is a chart illustrating compositions of examples of
the present disclosure;
[0012] FIG. 4 is a diagram for explaining a manufacturing method
according to an example of the present disclosure;
[0013] FIG. 5 is a diagram for explaining a manufacturing method
according to a comparative example of the present disclosure;
[0014] FIG. 6 is a chart illustrating magnetic performance
measurement results of examples of the present disclosure;
[0015] FIG. 7 is an element analysis result of an example of the
present disclosure;
[0016] FIG. 8 is Rietveld analysis results of an example of the
present disclosure;
[0017] FIG. 9 is Rietveld analysis results of an example of the
present disclosure;
[0018] FIG. 10 is Rietveld analysis results of an example of the
present disclosure; and
[0019] FIG. 11 is diagrams for explaining a manufacturing method
according to comparative examples of the present disclosure.
DESCRIPTION OF EMBODIMENTS
[0020] An embodiment of the present disclosure includes a main
phase containing: a rare earth element R of one or more types
including Nd; an element L of one or more types selected from a
group consisting of Co, Be, Li, Al, and Si; B; and Fe, wherein
crystals which form the main phase belong to P4.sub.2/mnm; some of
B atoms occupying a 4f site of the crystals are substituted with
atoms of the element L; each distribution of Nd atoms and the atoms
of the element L appears along a C-axis direction of the crystals
in a plurality of cycles; and an area where a cycle of the atoms of
the element L matches a cycle of the Nd atoms is included.
[0021] The main phase of the rare earth permanent magnet according
to the present disclosure has a crystal structure in which R--Fe--B
layers and Fe layers are layered alternately along the C-axis
direction. In the above-described embodiment, all the B atoms
occupying a specified site(s), except those required to maintain
the crystal structure, can be substituted with the atoms of the
element L.
[0022] Regarding the present disclosure, the carbon content in the
main phase is an ultramicro amount. Accordingly, C atoms in the
main phase can be hardly distributed at the site occupied by the B
atoms. As a result, the atoms of the element L tend to be easily
distributed at the site occupied by the B atoms. In other words,
the present disclosure can promote substitution of the B atoms
constituting the above-mentioned crystal structure with the atoms
of the element L by suppressing the carbon content in the main
phase. Consequently, the present disclosure can reduce suppression
of the magnetic moment of the Nd atoms by the B atoms. As a result,
residual magnetic flux density Br can be enhanced as the number of
the B atoms substituted with the atoms of the element L is
larger.
[0023] The carbon content in the main phase is reflected in a
distribution status of the atoms of the element L in the main
phase. Specifically speaking, when the carbon content is an
ultramicro amount, the distribution of the atoms of the element L
in the crystals of the main phase appears along the C-axis
direction of the crystals in a plurality of cycles and there is an
area where a cycle of the atoms of the element L matches a cycle of
the Nd atoms. Regarding a method for analyzing the distribution
status of atoms of the elements which constitute the present
disclosure, Three-dimensional Atom Probe (3DAP) and a Rietveld
method (Rietveld analysis) will be taken as examples. However, that
analysis method is not limited to the methods explained as examples
in this description.
[0024] In the present disclosure, a cycle of the atoms of the
element constituting the main phase is defined based on the
transition of the number of atoms of the relevant element in the
C-axis direction of the crystals which form the main phase.
Specifically speaking, one cycle of the atoms of the relevant
element is a section from a first inflection point at which the
number of atoms switches from a decrease to an increase through a
second inflection point at which the number of atoms switches from
the increase to a decrease to a third inflection point at which the
number of atoms switches again from the decrease to an increase.
When an n cycle and an (n+1) cycle are successive, the first
inflection point of the (n+1) cycle matches the third inflection
point of the n cycle.
[0025] In the present disclosure, when the cycle of the atoms of
the element L matches the cycle of the Nd atoms, it means a state
where one second inflection point of the atoms of the element L is
within one cycle of the Nd atoms. Such a state will be explained
with reference to FIG. 1 and FIG. 2. FIG. 1 and FIG. 2 are analysis
results by a 3DAP regarding the present disclosure. FIG. 1 is an
element analysis result regarding the present disclosure. Regarding
the element analysis performed to obtain FIG. 1, a distribution of
atoms of an element group consisting of Nd, B, C, and Co with
respect to crystals forming the main phase of the rare earth
permanent magnet was observed along the C-axis direction of the
crystals. FIG. 1A relates to Example 1 of the present disclosure
and FIG. 1B relates to Comparative Example 1 of the present
disclosure. In FIG. 1 and FIG. 2, Co is the element L.
[0026] FIG. 2 is created by enlarging and simplifying the part
enclosed with a frame line in FIG. 1A. Also, FIG. 2A indicated
above FIG. 2B is a diagram illustrating a structural model of the
crystals which form the main phase in an embodiment of the present
disclosure. Referring to FIG. 2A, the reference numeral 100
represents a crystal structure of a unit lattice. The crystal
structure 100 corresponds to the analysis result indicated in FIG.
2B. Specifically speaking, an area where the Nd atoms and the B
atoms are distributed at high concentration in FIG. 2B is indicated
as an R--Fe--B layer(s) 101 in FIG. 2A. The reference numeral 102
represents an Fe layer(s). The relevant crystals have a layered
structure, as illustrated in FIG. 2A, in which the Fe layers and
the R--Fe--B layers are layered alternately along the C-axis
direction. However, FIG. 2A is shown to explain that the crystal
structure of the main phase has the layered structure and does not
necessarily illustrate all the atoms constituting the
above-described crystal structure.
[0027] Referring to FIG. 2B, the reference numeral 200 represents a
first cycle of Co atoms. The reference numeral 201 represents a
first inflection point of the cycle 200, the reference numeral 202
represents a second inflection point of the cycle 200, and the
reference numeral 203 represents a third inflection point of the
cycle 200. The reference numeral 300 represents a first cycle of
the Nd atoms. The reference numeral 301 represents a first
inflection point of the cycle 300, the reference numeral 302
represents a second inflection point of the cycle 300, and the
reference numeral 303 represents a third inflection point of the
cycle 300. However, in this description, the expressions "first,"
"second," and so on attached to the respective cycles in this
description are used to distinguish these cycles from each other,
but are not intended to characterize the respective cycles unless
otherwise explained in this description. The second inflection
point 202 in the cycle 200 of Co appears in the cycle 300 of the Nd
atoms as illustrated in FIG. 2B. In other words, FIG. 1A and FIG.
2B illustrate the state where there is an area in which the cycle
of Co matches the cycle of the Nd atoms.
[0028] Moreover, in the present disclosure, there appear a
plurality of cycles of the constituent element group of the
crystals forming the main phase. For example, referring to FIG. 2B,
a second cycle 210 appeared successively following the first cycle
200 of the Co atoms. Specifically speaking, the third inflection
point 203 in the cycle 200 is at the same time a first inflection
point 211 in the cycle 210. The reference numeral 212 represents a
second inflection point in the cycle 210 and the reference numeral
213 represents a third inflection point in the cycle 210. The third
inflection point 203 in the first cycle 300 of the Nd atoms is at
the same time a first inflection point 311 in a second cycle 310 of
the Nd atoms. The reference numeral 312 represents a second
inflection point in the cycle 310 and the reference numeral 313
represents a third inflection point in the cycle 310.
[0029] In some embodiments of the present disclosure, 15 or more
cycles of the atoms of the element L match cycles of the Nd atoms.
As this embodiment will be explained by referring to FIG. 2B, the
inflection point 202 in the first cycle 200 of the Co atoms
appeared still during the first cycle 300 of the Nd atoms. Also,
the inflection point 212 in the second cycle 210 of the Co atoms
appeared still during the second cycle 310 of the Nd atoms
successively following the first cycle 300 of the Nd atoms.
Specifically speaking, referring to FIG. 2B, the area where the
cycle 200 and the cycle 210 appeared is an area where the Co atoms
successively matched two cycles of the Nd atoms. Since FIG. 2B is a
fragmentary enlarged view of FIG. 1A, it can be observed in actual
Example 1, as illustrated in FIG. 1A, that the area where two or
more cycles of the Co atoms successively match two or more cycles
of the Nd atoms exists. In some embodiments of the present
disclosure, 15 or more cycles of the atoms of the element L
matchcycles of the Nd atoms.
[0030] Regarding the present disclosure including this embodiment,
residual magnetic flux density Br is high. It is preferable that
the number of the cycles of the atoms of the element L successively
match the cycles of the Nd atoms be 15 cycles or more, more
preferably 20 cycles or more, and further preferably 30 cycles or
more. When the number of the cycles of the Nd atoms which
successively match the cycles of the atoms of the element L is less
than 15, invasion of the atoms of the element L into the main phase
reduces and, therefore, there is a high possibility that the amount
substituted with B atoms may become insufficient. In that case, it
becomes difficult to remarkably enhance the magnetic performance.
Meanwhile, in an embodiment where it is recognized that 50 or more
cycles of the Nd atoms successively match 50 or more cycles of the
atoms of the element L, it is presumed that there is theoretically
a high possibility that the crystal structure of the
above-mentioned main phase may not be maintained.
[0031] In some embodiments of the present disclosure, the area
where the cycles of the atoms of the element L match the cycles of
the Nd atoms can be defined by the distance of the C-axis direction
of the crystals forming the main phase. In some embodiments of the
present disclosure, the area where the cycles of the atoms of the
element L match the cycles of the Nd atoms exists in the length of
7 nm or more along the C-axis direction of the crystals forming the
main phase. In this embodiment, the definition of "the cycle(s) of
the atoms of the element L matches the cycle(s) of the Nd atoms"
has already been explained by taking an example of the relation
between the first and second cycles of the Nd atoms and the
inflection points of Co as illustrated in FIG. 2B. A case which
falls under this embodiment is where when the cycles of the atoms
of the element L successively match the cycles of the Nd atoms and
the number of cycles is the number of the cycles of the Nd atoms
and is defined as n, the distance from a first inflection point of
a first Nd atom cycle, which is a first end, to a third inflection
point of an n-th Nd atom cycle which is a second end on the
opposite side of the first end of the relevant area as measured
along the C-axis direction is 7 nm or more.
[0032] The above-described distance should preferably be 14 nm or
more, more preferably 20 nm or more. When the distance is less than
7 nm, the invasion of the element L into the main phase becomes
insufficient and, therefore, desired magnetic performance can
hardly be exhibited.
[0033] Regarding the crystals which form the main phase of the
present disclosure, there exist two 16k sites, two 8j sites, one 4g
site, two 4f sites, one 4e site, and one 4c site. In the following
explanation, when there are a plurality of sites like the 16k
sites, the sites may sometimes be described as a first 16k and a
second 16k. However, the expressions "first," "second," and so on
are used to distinguish the sites and are not intended to
characterize the respective sites unless otherwise explained in
this description.
[0034] In the present disclosure, some of the B atoms occupying the
4f site are substituted with the element L. Moreover, in some
embodiments of the present disclosure, not only the B atoms
occupying the 4f site, some of atoms of one or more types selected
from a group consisting of the Nd atoms occupying the 4f site of
the crystals belonging to P4.sub.2/mnm and Fe atoms occupying the
8j site are substituted with the atoms of the element L.
Incidentally, in some embodiments of the present disclosure, the
possibility of some of the Fe atoms occupying the 4c site being
substituted with the atoms of the element L cannot necessarily be
excluded.
[0035] Regarding the layered structure of the R--Fe--B layers and
the Fe layers, atoms of the element R occupying the first 4f site
and the 4g site, the Fe atoms occupying the 4c site, and the B
atoms occupying the second 4f site form the R--Fe--B layer. The Fe
atoms occupying two 16k sites, two 8j sites, and a 4e site form the
Fe layer.
[0036] In some embodiments of the present disclosure, whether some
of the specified atoms are substituted with the atoms of the
element L or not is judged by the Rietveld method. Specifically
speaking, whether the substitution is performed or not is judged
based on a space group of the crystals forming the main phase which
is specified by analysis and occupancy rates of the respective
elements at each site existing in the space group. However, the
present disclosure does not exclude the judgment on whether the
specified atoms in the crystal structure of the rare earth
permanent magnet are substituted or not, according to a method
different from the Rietveld method.
[0037] Regarding the above-mentioned judgment on the substitution
by the atoms of the element L, an explanation will be provided by
taking, as an example, an embodiment in which the B atoms occupying
the 4f site of P4.sub.2/mnm are substituted with the atoms of the
element L. The same method can be also used for the judgment on the
substitution of atoms occupying other sites including a case where
the Nd atoms occupying the 4f site and the Fe atoms occupying the
8j site are substituted.
[0038] The crystals which form the main phase of the present
disclosure belong to P4.sub.2/mnm. An occupancy rate of the atoms
of the element L of the relevant space group at the 4f site of
occupied by the B atoms is defined as p. When the occupancy rate
which is defined as p is expressed in percentage, it is expressed
as (p.times.100)%. When the occupancy rate is p>0.000, it can be
judged that some of the B atoms occupying the 4f site are
substituted with the atoms of the element L. On the other hand,
when the occupancy rate is p.ltoreq.0.000, it can be judged that
some of the B atoms occupying the 4f site are not substituted with
the atoms of the element L Furthermore, even when the occupancy
rate is p>0.000, if the occupancy rate of the substituted atoms
becomes a negative value, it lacks physical consistency and,
therefore, it is sometimes impossible to judge whether the
substitution has been performed or not. Incidentally, the occupancy
rate of the B atoms which occupy the 4f site together with the
atoms of the element L is defined as 1.000-p; and when this
occupancy rate of the B atoms is expressed in percentage, it is
expressed as [(1.000-p).times.100]%.
[0039] An upper limit of the occupancy rate p of the atoms of the
element L is not limited as long as the crystal structure of the
main phase is maintained. Regarding the element L which substitutes
the B atoms occupying the 4f site, an embodiment in which p is
calculated within the range of 0.030.ltoreq.p.ltoreq.0.100 is
preferred. From the viewpoint of reliability of the analysis
result, an s value is 1.3 or less; and the s value closer to 1 is
more preferable and the most preferable s value is 1. The s value
is a value which can be obtained by dividing an R-weighted pattern
(R.sub.wp) of the reliability factor R by R-expected (R.sub.e).
[0040] An embodiment of the present disclosure includes the main
phase containing one or more types of selected rare earth
element(s) R including Nd, the element of one or more types
selected from a group consisting of Co, Be, Li, Al, and Si, B, and
Fe. In the present disclosure, the rare earth elements R are Nd, Pr
(praseodymium), Dy (dysprosium), Tb (terbium), Sm (samarium), Gd
(gadolinium), Ho (holmium), and Er (erbium). Pr is preferred as the
rare earth element to be used together with Nd from the viewpoint
of reduction of the manufacturing cost. However, if the content of
the rare earth elements other than Nd becomes too large, there is a
high possibility that the residual magnetic flux density Br may
reduce. Therefore, a preferred ratio of the number of atoms of Nd
to the other rare earth elements R is 80:20 to 70:30. Furthermore,
in this description, the element of one or more types selected from
the group consisting of Tb, Sm, Gd, Ho, and Er may sometimes be
described as element A as an element which contributes to
enhancement of the magnetic performance.
[0041] Some embodiments of the present disclosure contain the
element A of one or more types selected from the group consisting
of Tb, Sm, Gd, Ho, and Er. The present disclosure can further
enhance the residual magnetic flux density Br by containing Sm and
Gd. Also, the present disclosure can enhance a coercive force Hcj
by containing Tb, Ho, and Er. Therefore, both the residual magnetic
flux density Br and the coercive force Hcj can be enhanced by
reducing the carbon content, substituting B with the specified
element L, and containing the element A. The element A can be
substituted with Fe.
[0042] The ratio of the number of atoms of B to the element L (B:
element L) is expressed as (1-x):x, where x satisfies
0.01.ltoreq.x.ltoreq.0.25, preferably 0.03.ltoreq.x.ltoreq.0.25. In
a case of x<0.01, the magnetic moment reduces. In a case of
x>0.25, the specified crystal structure cannot be
maintained.
[0043] In some embodiments of the present disclosure, this
embodiment not only suppresses the B content, but also controls the
carbon content and thereby suppresses the invasion of the C atoms
into the main phase in order to obtain the crystal structure to
substitute the B atoms with the atoms of the element L. Known
methods for controlling the carbon content include selection of
materials for jigs, indirect heating, and no gas flow etc. However,
it is preferable that the above-listed known control methods and a
new different method be combined in order to manufacture some
embodiments of the present disclosure. As some embodiments of the
present disclosure are manufactured through the process of the new
method, they can reduce the carbon content in the main phase and
include a specified element distribution. The new method for
controlling the carbon content relating to the present disclosure
will be explained later.
[0044] In some embodiments of the present disclosure, an
unsubstituted element L which has not been substituted with any of
the rare earth element R, Fe, or B, the element A, and also other
elements contained in the raw material alloy exist in any one of
the sites of the Nd--Fe--B layer. Examples of the other elements
include known elements which enhance the magnetic performance of
the rare earth permanent magnet. Furthermore, elements which form a
grain boundary phase such as Cu, Nb, Zr, Ti, and Ga, and elements
which form a subphase such as O (oxygen) may sometimes enter any
one of the sites of the crystal structure of the main phase.
[0045] In some embodiments of the present disclosure, a composition
of the respective elements contained in the present disclosure is
as follows: the content of the rare earth element R excluding the
element A to the entire weight of the rare earth element is 20 to
35 wt %, preferably 22 to 33 wt %. The B content is 0.80 to 1.1 wt
%, preferably 0.82 to 0.98 wt %.
[0046] The total content of the element of one or more types
selected from a group consisting of Co, Be, Li, Al, Si, Cu, Nb, Zr,
Ti, and Ga is 0.8 to 2.0 wt %, preferably 0.8 to 1.5 wt %.
Regarding the group of the above-listed elements, an element group
consisting of Co, Be, Li, Al, and Si can invade, as the element L,
into the main phase and substitute the specified B atoms.
Furthermore, an element group consisting of Al, Cu, Nb, Zr, Ti, and
Ga can precipitate as the grain boundary phase or the subsidiary
phase. Regarding an element like Al which belong both the above two
element groups, which one of the main phase, the grain boundary
phase, and the subphase it should be contained in is determined
depending on manufacturing conditions.
[0047] The total content of the element A of one or more types
selected from a group consisting of Tb, Sm, Gd, Ho, and Er is 2.0
to 10.0 wt %, preferably 2.6 to 5.4 wt %. The residue is Fe. The
present disclosure may sometimes contain C in an unavoidable amount
in terms of manufacture. However, the content of C is a trace
amount, preferably 0.09 wt % or less, more preferably 0.05 wt % or
less, or further preferably 0.03 wt % or less. In the present
disclosure, most of the C atoms exist in the grain boundary phase
and the C atoms which invade into the main phase are of an
ultramicro amount. Therefore, the C atoms do not exert any
significant influence on the magnetic performance.
[0048] By preparing the composition to be within the
above-described range, the present disclosure includes the main
phase formed by crystals in which the elements are distributed in
some specified forms. Consequently, good residual magnetic flux
density Br and coercive force Hcj are exhibited. Regarding the
composition of the present disclosure, the content of each element
is an actual measured value of the present disclosure. Regarding
measurement equipment, an ICP emission spectrometer ICPS-8100 by
SHIMADZU CORPORATION can be indicated as an example. Moreover,
regarding equipment to be used for composition analysis of
trace-amount elements in the main phase such as C, N, and O,
LEAP3000XSi by AMETEK can be indicated as an example. When
LEAP3000XSi by AMETEK is used, the analysis can be performed by
setting a laser pulse mode (laser wavelength=532 nm), laser
power=0.5 nJ, and a sample temperature=50 K. When the actual
measured value is unknown, a charge amount of the raw material
alloy prepared when manufacturing the relevant rare earth permanent
magnet is considered to be the actual measured value of each
element in the rare earth permanent magnet. The relevant charge
amount is the content of an element source in raw material metals
to be added to the raw material alloy.
[0049] The present disclosure has high residual magnetic flux
density Br and can further have a high coercive force Hcj and a
large maximum energy product BH.sub.max. Moreover, when the present
disclosure contains, for example, Ho as the element A, it also has
excellent heat resistance.
[Rare Earth Permanent Magnet Manufacturing Method]
[0050] A rare earth permanent magnet manufacturing method of the
present disclosure is not particularly limited as long as it can
provide operational advantages of the present disclosure. An
embodiment of the present disclosure regarding the rare earth
permanent magnet manufacturing method includes a carbon reduction
step and a degreasing step. The carbon content which invades into
the main phase can be reduced by providing the carbon reduction
process. As a result, specified atoms in the main phase can be
easily substituted with the atoms of the element L.
[0051] The present disclosure is a rare earth permanent magnet
manufacturing method including: a degreasing process of retaining,
in vacuum, a green compact of a raw material alloy containing a
rare earth element R of one or more types including Nd, an element
of one or more types selected from a group consisting of Co, Be,
Li, Al, Si, Cu, Nb, Zr, Ti, and Ga, B, and Fe; and a carbon
reduction step of reducing a carbon content in the green compact
before the degreasing process.
[0052] In some embodiments of the present disclosure, the carbon
reduction process includes a degassing step of retaining the green
compact at a temperature of 100.degree. C. or lower for one hour or
longer before the degreasing step. In some embodiments of the
present disclosure, the carbon reduction step includes a drying
process of retaining the green compact in an atmosphere of a dew
point of -60.degree. C. or lower before the degreasing step. In
some embodiments of the present disclosure, the drying process is
performed after the degassing process.
[0053] In the present disclosure, a fine mill process of the raw
material alloy and magnetic field press process are performed
before the carbon reduction process. The green compact of the raw
material allow is produced by these processes. In each of the
processes, for example, materials to be carbon sources such as oil
added as a binder and oil from equipment, plastics, and paper are
used. Also, matters attached to the inside of a furnace can be the
carbon sources. The present disclosure reduces the binder to be
added to the green compact by executing the degassing step and the
drying step on the green compact. Furthermore, any contact between
the green compact and the carbon sources is avoided during these
steps to the extent possible. As a result, the present disclosure
can produce the green compact with a small carbon content.
Regarding the rare earth permanent magnet which is made of the
above-mentioned green compact, the C atoms can hardly invade into
the main phase. Therefore, in the present disclosure, the
substitution of the specified B atoms constituting the main phase
by the atoms of the element L is promoted. As a result, the present
disclosure can manufacture a rare earth permanent magnet which
exhibits high residual magnetic flux density Br.
[0054] Some embodiments of the present disclosure include: a
sintering process of sintering the green compact after the
degreasing process; and a heat treatment process of applying a heat
treatment to a sintered compact produced in the sintering process
at a temperature lower than a sintering temperature. As a result of
this, the grain boundary phase and the subsidiary phase precipitate
other than the main phase, thereby making it possible to
manufacture a rare earth permanent magnet with further excellent
magnetic performance.
[Micronization Step]
[0055] The raw material alloy is prepared at a stage prior to the
fine mill process. The raw material alloy is obtained by: charging
raw material metals containing the rare earth element R of one or
more types including Nd, the element of one or more types selected
from a group consisting of Co, Be, Li, Al, Si, Cu, Nb, Zr, Ti, and
Ga, Fe, and B so that the respective elements mentioned above will
be contained at a specified stoichiometric ratio; and dissolving
the charged raw material metals.
[0056] The stoichiometric ratio of the raw material alloy is almost
the same as the composition of the rare earth permanent magnet
which is an end product. Therefore, a blending ratio of the raw
material materials used for the raw material alloy is determined
according to a desired composition of the rare earth permanent
magnet. It is preferable that the raw material alloy should not be
an amorphous alloy. It is also preferable that the element A of one
or more types selected from a group consisting of Tb, Sm, Gd, Ho,
and Er should be contained in the raw material alloy in order to
enhance the magnetic performance.
[0057] In the fine mill process, the raw material alloy is coarsely
ground, for example, in an inert gas atmosphere such as argon by
using a ball mill, a jet mill, or so on. It is preferable that the
raw material alloy be embrittled before it is coarsely ground. A
powder particle size D.sub.50 of alloy particulates is preferably 2
to 25 .mu.m, more preferably 2 to 18 .mu.m, and further preferably
2 to 15 .mu.m. In this embodiment, D.sub.50 is a median diameter in
cumulative distribution of an alloy particulate group on the
volume-basis. The powder particle size of the alloy particulates is
not particularly limited and can be measured by using, for example,
a laser diffraction type particle size analyzer (SALD3100 by
SHIMADZU CORPORATION). By employing the powder particle size within
the above-mentioned preferable range, it becomes easier to sintered
particle refinement of the sintered compact, which is obtained by
sintering the raw material alloy, into a desired sintered particle
size. It is also preferable that the raw material alloy
particulates which have been coarsely ground should be further
fine-milled by using the ball mill, the jet mill, or the like.
[Molding Process in Magnetic Field]
[0058] In the molding process in the magnetic field, the obtained
raw material alloy particulates are compression-molded in a
magnetic field. This process should preferably be executed with the
magnetic field intensity of between 0.8 MA/m and 4.0 MA/m,
inclusive, and the pressure of between 1 MPa and 200 MPa,
inclusive. There is no particular limitation on a binder as long as
it can exert the operational advantages of the present disclosure;
and an example of the binder can be a fatty acid ester diluted with
a solvent. Examples of the fatty acid ester can include methyl
caproate, methyl caprylate, methyl laurate, and lauryl methyl
sulfate. Examples of the solvent can include petroleum solvents
represented by isoparaffin and naphthene solvents. A mixture
example of the fatty acid ester and the solvent can be a mixture
with a weight ratio of 1:20 to 1:1. Additionally, 1.0 wt % or less
an arachic acid may be contained as a fatty acid. Moreover, a solid
lubricant such as zinc stearate may be also used instead of a
liquid lubricant or together with the liquid lubricant.
[Carbon Reduction Process (Degassing Step)]
[0059] The present disclosure can reduce the carbon content in the
green compact by executing the degassing step and the drying step
outside a sintering furnace before the degreasing step as compared
to the case where only the degreasing step is executed before the
sintering step. The reduction of the carbon content can be
implemented by executing either one of the degassing step and the
drying step, but both the steps may be executed. When both the
steps are executed, the drying step should preferably be executed
after the degassing step. By executing the carbon reduction step,
the carbon content in the rare earth permanent magnet becomes an
ultramicro amount and the carbon content becomes less than the
carbon content of the case where the carbon atoms can easily invade
into the main phase of the rare earth permanent magnet. In other
words, it becomes difficult for the C atoms to invade into the main
phase by executing the carbon reduction step according to the
present disclosure, this makes it easier for the specified the B
atoms to be substituted with the atoms of the element L.
[0060] In the degassing step, the green compact is placed in a
sealable treatment container and is retained under a temperature
condition of 100.degree. C. or lower, preferably 40.degree. C. or
lower, or more preferably 30.degree. C. or lower. In this step, the
carbon content can be reduced more when the retention time is
longer. On the other hand, if the retention time is too long,
evaporation of the binder proceeds, so that a protective membrane
of the green compact will be lost. Therefore, from the viewpoint of
effective reduction of the carbon content and avoidance of
oxidation of the green compact, the retention time is one hour or
more, preferably 6 hours or more, or more preferably between 12
hours and 24 hours, inclusive. In some embodiments of the present
disclosure, when the degassing step is executed for the
above-described preferable retention time, a weight reduction rate
after the degassing step to the weight of the green compact before
the degassing step is approximately 20% to 40% inclusive. In this
case, it is possible to maintain the state where the binder in the
amount which can become the protective membrane is attached to the
particles in the green compact.
[Carbon Reduction Process (Drying Step)]
[0061] In the drying step, the green compact is placed in the
sealable treatment container and is retained by keeping the inside
of the treatment container in a low humidity environment. When the
drying step is executed after the degassing step, the drying step
may be executed continuously in the same treatment container where
the degassing step has been executed. In the present disclosure,
the low humidity environment means the atmosphere where the dew
point is -60.degree. C. or lower, preferably -80.degree. C. or
lower, or more preferably -110.degree. C. or lower. The retention
time is preferably between 6 hours and 96 hours, inclusive, or more
preferably between 24 hours and 96 hours, inclusive. Consequently,
the carbon content is reduced and the green compact which hardly
oxidizes can be produced. When the retention time is less than 24
hours, the property will degrade due to oxidization. Furthermore,
when the retention time exceeds 96 hours, the magnetic property
will degrade due to oxidization.
[Carbon Reduction Process (Degreasing Step)]
[0062] After the carbon reduction step, the green compact is moved
to a sintering furnace and the degreasing step is started. In the
degreasing step, it is preferable that temperature management in a
single stage or a plurality of stages be performed in order to
degrease the entire green compact uniformly and the degree of
vacuum within the sintering furnace be maintained at 10 Pa or less,
preferably 10.sup.-2 Pa or less. Accordingly, the carbons remaining
in the green compact after the carbon reduction step can be further
reduced and the main phase of the rare earth permanent magnet can
be made to have the crystal structure with desired element
distribution.
[0063] A preferred example of the temperature management is to
maintain the temperature at between 50.degree. C. and 150.degree.
C., inclusive, for not less than one hour and not more than four
hours and then raise and maintain the temperature at between
150.degree. C. and 250.degree. C., inclusive, for not less than one
hour and not more than four hours. When an internal furnace
temperature of the first stage is set to be lower than 50.degree.
C., oxidation and degreasing time of the green compact within the
furnace is unbalanced and the green compact tends to be easily
oxidized. When the internal furnace temperature is set at
150.degree. C. or higher, thermal decomposition of the binder
proceeds rapidly (the pressure increases in a spike manner), the
degree of vacuum tends to easily decrease, and it becomes difficult
to maintain a desired degree of vacuum. When the internal furnace
temperature at the second and subsequent stages is set to be lower
than 150.degree. C., degreasing has been performed in the first
stage, but decreasing in the second stage requires time and,
therefore, oxidation tends to be caused easily. When the internal
furnace temperature is set at 250.degree. C. or higher, the degree
of vacuum tends to easily decreases and it becomes difficult to
maintain the desired degree of vacuum.
[Sintering Process]
[0064] The sintering step is executed by retaining the green
compact inside the sintering furnace after the degreasing step and
raising the internal furnace temperature. The main phase of the
rare earth permanent magnet specified by the present disclosure can
be formed by executing the sintering step. The present disclosure
executes the above-described carbon reduction step before placing
the green compact in the sintering furnace. Accordingly, spike
waveforms hardly occur in transition of the degree of vacuum within
the sintering furnace. In other words, the rare earth permanent
magnet can be manufactured by maintaining the safety of an internal
furnace environment of the sintering furnace. The temperature
management within the sintering furnace in the sintering step and
the heat treatment step is decided based on melting points of
components of the green compact.
[0065] An example of the temperature management within the
sintering furnace in the sintering step of the present disclosure
can be an embodiment in which the temperature is retained at
between 1000.degree. C. and 1200.degree. C., inclusive, for not
less than 2 hours and not more than 11 hours. Another preferred
example of the temperature management can be to retain the
sintering temperature at between 1000.degree. C. and 1100.degree.
C., inclusive, and for not less than 3 hours and not more than 7
hours.
[0066] As a result, an embodiment of the present disclosure can
manufacture the rare earth permanent magnet including the main
phase, in high density, containing the rare earth element R of one
or more types including Nd, the element L, B, and Fe, wherein its
crystals belong to P4.sub.2/mnm; some of B atoms occupying the 4f
site of the crystals are substituted with atoms of the element L;
each distribution of the Nd atoms and the atoms of the element L
appears along the C-axis direction of the crystals in a plurality
of cycles; and the main phase includes an area where a cycle(s) of
the atoms of the element L matches a cycle(s) of the Nd atoms is
included. When the temperature conditions and the retention time of
the above-described preferred examples of the temperature
management are not satisfied, it becomes difficult to form the
specified main phase of the present disclosure.
[0067] Regarding the main phase formed by some embodiments of the
present disclosure, 15 or more cycles of the atoms of the element L
successively match 15 or more cycles of the Nd atoms in the
above-described area where the cycles of the atoms of the element L
match the cycles of the Nd atoms. Furthermore, regarding the main
phase formed by some embodiments of the present disclosure, the
distance of the C-axis direction of the relevant crystals in the
area where the cycles of the atoms of the element L match the
cycles of the Nd atoms is 7 nm or more.
[0068] Regarding the main phase formed by some embodiments of the
present disclosure, the main phase in which some of atoms of one or
more types selected from a group consisting of not only the B atoms
occupying the 4f site of the crystals belonging to P4.sub.2/mnm,
but also the Nd atoms occupying the 4f site, the Fe atoms occupying
the 4c site, and the Fe atoms occupying the 8j site are substituted
with the atoms of the element L is formed according to the
composition of the raw material alloy, the conditions of the carbon
reduction step, and the temperature management of each step.
Additionally, the present disclosure also includes an embodiment
that forms the main phase containing the element A when the element
A is added to the raw material alloy.
[0069] When any one of the main phases illustrated as examples
above is formed, the present disclosure can also enhance the
residual magnetic flux density Br, the coercive force Hcj, the
maximum energy product BHmax, and the mechanical strength of the
rare earth permanent magnet.
[Heat Treatment Process]
[0070] The heat treatment step is executed after the sintering step
by setting the internal furnace temperature at a specified heat
treatment temperature. The grain boundary phase and the subsidiary
phase can be made to precipitate around the main phase of the
specified rare earth permanent magnet of the present disclosure by
executing the heat treatment step.
[0071] The heat treatment step is executed in a single stage or a
plurality of stages. An example of the temperature management
inside the sintering furnace in the heat treatment step can be to
retain the temperature at between 400.degree. C. and 1100.degree.
C., inclusive, and for not less than 2 hours and not more than 9
hours. According to the present disclosure, Cu, Nb, Zr, Ti, Ga,
etc. can be contained in the grain boundary phase. A phase
containing oxygen and so on can precipitate as the subsidiary
phase.
[0072] In some embodiments of the present disclosure, the heat
treatment step is executed after the sintering step and the
internal furnace temperature is further controlled in a state of
maintaining the degree of vacuum and eventually decreased to room
temperature, and then the green compact is sintered to manufacture
the rare earth permanent magnet. The above-described temperature
control causes the grain boundary phase and the subsidiary phase to
precipitate in a metallographic structure.
[0073] An average sintered particle size in some embodiments of the
present disclosure is 110 to 130% of a powder particle size of the
green compact and can be 110 to 180% of the powder particle size of
the green compact. The average sintered particle size is preferably
between 2.2 .mu.m and 20 .mu.m, inclusive, more preferably between
2.2 .mu.m and 15 .mu.m, inclusive, or further preferably between
2.2 .mu.m and 10 .mu.m, inclusive. When the average sintered
particle size exceeds 20 .mu.m, the coercive force Hcj degreases
significantly. In the present disclosure, the average sintered
particle size is an average value of a major axis of a particle
group constituting the sintered compact. The major axis of the
particle group constituting the sintered compact can be measured by
observation with an optical microscope or image analysis of
sectional images obtained by a scanning electron microscope.
[0074] Sintered density in some embodiments of the present
disclosure is 6.0 to 8.0 g/cm.sup.3 and may sometimes become 7.2 to
7.9 g/cm.sup.3. When the sintered density is less than 6.0
g/cm.sup.3, there will be many voids in the sintered compact. As a
result, the residual magnetic flux density Br and the coercive
force Hcj of the rare earth permanent magnet decrease.
EXAMPLES
[0075] This embodiment will be further explained by referring to
the following examples. However, this embodiment is not limited to
the following examples.
Examples 1 to 4 and Comparative Examples 1 to 3
[0076] Example 1 to Example 4 and Comparative Example 1 to
Comparative Example 3 were manufactured and the magnetic
performance was measured. Example 1 to Example 3 and Comparative
Example 1 to Comparative Example 3 constitute Set 1 composed of
Example 1 and Comparative Example 1, Set 2 composed of Example 2
and Comparative Example 2, and Set 3 composed of Example 3 and
Comparative Example 3. Regarding Example 1, Comparative Example 1,
and Example 4, element analysis of the main phase by a 3DAP and
crystal structure analysis of the main phase by the Rietveld method
were conducted.
[0077] Chemical composition of charged amount of the raw material
alloy for each of Examples and Comparative Examples was decided in
accordance with a desired composition of the rare earth permanent
magnet. FIG. 3 is a table illustrating the compositions of examples
of the present disclosure. When "-" is indicated in an upper field,
it means that "the raw material metal which becomes the element
source was not added." A lower field is for an actual measured
value of the element to be contained in the rare earth permanent
magnet, which was measured by using an ICP emission spectral
analysis method (Inductively Coupled Plasma Atomic Emission
Spectroscopy: ICP-AES); and when "-" is indicated in the lower
field, it means that "the relevant element was not detected" or
"the relevant element has not been measured yet."
[0078] A manufacturing method of Example 1 will be explained. A raw
material alloy prepared with the charged composition described in
FIG. 3 was coarsely ground with a ball mill, thereby obtaining
alloy particles. Then, the alloy particles were dispersed in a
solvent. An additive was introduced to the dispersed solution,
which was then stirred to cause a reduction, thereby micronizing
the alloy particles. A molding cavity was loaded with the
micronized raw material alloy and the binder and molding in a
magnetic field was performed at 0.8 MA/m or more and 20 MPa,
thereby preparing the green compact.
[0079] The carbon reduction step was executed by placing the green
compact in a glove box. In the carbon reduction step, the degassing
step and the drying step were executed. In the degassing step, a
temperature condition of 25.degree. C. was retained for 24 hours.
Then, the drying step was executed within the same glove box. In
the drying step, the atmosphere at a dew point of -80.degree. C.
was retained for 24 hours.
[0080] After the drying step terminated, the green compact was
moved from the glove box to the sintering furnace and the
degreasing step was started. In the degreasing step, the internal
furnace temperature was set and maintained at 200.degree. C. for 3
hours and then set and maintained at 300.degree. C. for 3 hours in
order to cause the degree of vacuum to reach 10.sup.-2 Pa.
[0081] After the degreasing step terminated, the sintering step was
executed. In the sintering step, the internal furnace temperature
was set and maintained at 1070.degree. C. for 4 hours. FIG. 4
illustrates a profile of the temperature and the degree of vacuum
in the degreasing step and the sintering step of Example 1. The
sintered compact was taken out of the sintering furnace, thereby
obtaining Example 1. There was a tendency that the metallographic
structure of Example 1 was composed generally of the main
phase.
[0082] In Comparative Example 1, a raw material alloy with the
composition indicated in FIG. 3 was used and the micronization
step, the molding step in the magnetic field, the degassing step,
the drying step, and the degreasing step were executed under the
same conditions as in Example 1. FIG. 5 illustrates a profile of
the temperature and the degree of vacuum in the degreasing step and
the sintering step of Comparative Example 1. In the sintering step
of Comparative Example 1, the internal furnace temperature was
maintained at 1080.degree. C. for 4 hours as illustrated in FIG. 5.
There was a tendency that the metallographic structure of
Comparative Example 1 was composed generally of the main phase.
[0083] In Example 2 and Comparative Example 2, raw material alloys
with the compositions indicated in FIG. 3 were used and the
micronization step, the molding step in the magnetic field, the
degreasing step, and the sintering step were executed under the
same conditions as in Example 1. In Example 2, the degassing step
and the drying step were executed under the same conditions as in
Example 1. On the other hand, in Comparative Example 2, neither the
degassing step nor the drying step was executed. In both Example 2
and Comparative Example 2, there was a tendency that the
metallographic structure was composed generally of the main
phase.
[0084] In Example 3 and Comparative Example 3, raw material alloys
with the compositions indicated in FIG. 3 were used and the
micronization step, the molding step in the magnetic field, the
degassing step, the drying step, the degreasing step, and the
sintering step were executed under the same conditions as in
Example 1. In both Example 3 and Comparative Example 3, there was a
tendency that the metallographic structure was composed generally
of the main phase.
[0085] In Example 4, a raw material alloy with the composition
indicated in FIG. 3 was used and the micronization step, the
molding step in the magnetic field, the degassing step, and the
drying step were executed under the same conditions as in Example
1. In the degreasing step, the internal furnace temperature was set
and maintained at 200.degree. C. for one hour and then set and
maintained at 300.degree. C. for 3 hours in order to cause the
degree of vacuum to reach 10.sup.-2 Pa. In the sintering step, the
internal furnace temperature was maintained at 1060.degree. C. for
4 hours. Subsequently, the heat treatment step was executed.
Regarding the metallographic structure of Example 4, there was a
tendency that the grain boundary phase and the subsidiary phase
were also formed other than the main phase.
[0086] FIG. 6 illustrates the magnetic performance of Example 1 to
Example 4 and Comparative Example 1 to Comparative Example 3. An
apparatus equivalent to TPM-2-08S pulsed high field magnetometer
equipped with a sample temperature variable device by TOEI INDUSTRY
CO., LTD. was used as measurement equipment. The carbon content of
Examples was less than that of Comparative Examples in either one
of Set 1 to Set 3 as illustrated in FIG. 3. Accordingly, as
illustrated in FIG. 6, the residual magnetic flux density Br of
each Example became higher than that of Comparative Example
belonging to the same set.
[0087] The element distribution in the C-axis direction was
analyzed with respect to the crystals of the main phase in Example
1, Comparative Example 1, and Example 4 by using the 3DAP.
Equipment and measurement conditions used for the analysis are
described below.
Equipment Name: LEAP3000XSi (by AMETEK)
[0088] Measurement Conditions: laser pulse mode (laser
wavelength=532 nm) laser power=0.5 nJ, sample temperature=50K
[0089] FIG. 1 illustrates element analysis results of Example 1 and
Comparative Example 1 and FIG. 1A illustrates the element analysis
result of Example 1 and FIG. 1B illustrates the element analysis
result of Comparative Example 1. As a result of comparison between
FIG. 1A and FIG. 1B, FIG. 1A regarding Example 1 shows that cycles
of both Co and Nd appeared successively. Also, 24 cycles of Co
successively matched 24 cycles of the Nd atoms. Furthermore, the
distance of the C-axis direction of the crystals in the area where
the cycles of the Co atoms matched the cycles of the Nd atoms was
14 nm or more. On the other hand, FIG. 1B regarding Comparative
Example 1 shows that the cycles of Co did not appear so notably as
in FIG. 1A. Accordingly, there were less areas in Comparative
Example 1 than in Example 1 where the cycles of Co matched the
cycles of the Nd atoms, and the distance of the C-axis direction of
the crystals in the relevant area was shorter than that in Example
1.
[0090] Example 1 was prepared by adjusting, for example, the amount
of carbons included in raw materials containing the carbons such as
pure iron which is a raw material so that the carbon content in the
raw material alloy becomes less than that of Comparative Example 1.
Accordingly, the amount of carbons which invaded into the main
phase of the rare earth permanent magnet of Example 1 was less than
that of Comparative Example. According to the element distribution
result illustrated in FIG. 1A, the carbon content was an ultramicro
amount in Example 1 and, therefore, it is surmised that regarding
the carbons, for example, substitution with atoms other than the B
atoms, such as the Fe atoms, preceded and no substitution by the C
atoms occurred at most of the sites occupied by the B atoms.
[0091] FIG. 7 illustrates the element analysis result of the rare
earth permanent magnet with the same composition as that of Example
4. Regarding the element analysis result of Example 4, the
existence of an area where cycles of the Co atoms matched cycles of
the Nd atoms was confirmed as in Example 1. As illustrated in FIG.
7, at least 27 cycles of the Co atoms matched at least 27 cycles of
the Nd atoms and the distance of the C-axis direction of the
relevant area was approximately 14 nm.
[0092] FIG. 8 and FIG. 9 are analysis results by the Rietveld
method of Example 1 and Comparative Example 1. Equipment used and
usage conditions are described below. Analysis software used is
IETAN-FP.
[0093] Analysis Apparatus: horizontal X-ray diffractometer SmartLab
by Rigaku Corporation Analysis Conditions:
Target: Cu
[0094] Monochromator: use symmetric Johansson-type Ge crystals
(CuK.alpha.1) on incidence side Target Output: 45 kV-200 mA
Detector: one-dimensional detector (HyPix3000) (Normal
Measurement): .theta./2.theta. scan Entrance Slit System:
divergence 1/2.degree.
Slit Light-Receiving System: 20 mm
[0095] Scan Speed: 1.degree./min
Sampling Width: 0.01.degree.
Measuring Angle (28): 10.degree. to 110.degree.
[0096] FIG. 8 and FIG. 9 are diagrams for explaining crystal
structure analysis of Examples of the present disclosure. As a
result of the analysis, a lattice constant of Example 1 was
successfully identified as indicated in FIG. 8A. FIG. 8B indicates
ICSD and literature data to which reference was made. It was
successfully identified based on the analysis result indicated in
FIG. 8 that the crystals of the main phase of this embodiment
belong to P4.sub.2/mnm. Regarding also Comparative Example 1, a
lattice constant and an identification method were analyzed by the
Rietveld method and the same analysis results as those of Example 1
were obtained. Specifically speaking, the lattice constant and
literature data to which reference was made in Comparative Example
1 were the same as those in FIG. 8A and FIG. 8B relating to Example
1.
[0097] Subsequently, fitting of an X-ray diffraction pattern of
Example 1 with a model pattern was performed. The model pattern is
a pattern obtained by combining calculation results of X-ray
diffraction patterns of, for example, NdO crystals and arbitrary
Nd.sub.2Fe.sub.14B crystals. The arbitrary Nd.sub.2Fe.sub.14B
crystals mean crystals obtained by simulation to change an
arbitrary crystal parameter of known Nd.sub.2Fe.sub.14B crystals
and cause atoms occupying an arbitrary one site existing in the
space group to be substituted with the atoms of the element L (Co
in Example 1). A fitting index is expressed as an s value and the
analysis was conducted so that the s value would become a value
close to 1. The s value is defined as s=R.sub.wp/R.sub.e. Fitting
results of R.sub.wp=2.141, R.sub.e=1.798, s=1.1907 were obtained by
means of simulation.
[0098] A plurality of model patterns were further analyzed in order
to obtain a model whose s value would become smaller than the model
pattern which obtained the above-described fitting result. As a
result, FIG. 9 illustrates the analysis result of the model pattern
with a further smaller s value. In a "Judgment" column of FIG. 9,
".smallcircle." means that the atoms occupying the relevant site
were substituted with the atoms of the element L (the Co atoms in
FIG. 9) (an occupancy rate value of the Co atoms is more than 0 and
1 or less); "x" means that the atoms occupying the relevant site
were not substituted with the atoms of the element L (the Co atoms
in FIG. 9) (the occupancy rate value of the Co atoms is 0 or less);
and ".DELTA." means that no judgment could not be made because the
result lacked physical consistency (the occupancy rate value of the
Co atoms is more than 1).
[0099] Referring to FIG. 9, the occupancy rates of the Co atoms at
the respective sites are: 0.0349 at the 4f site occupied by the B
atoms; 0.0252 at the second 4f site occupied by the Nd atoms; and
0.9211 at the first 8j site occupied by the Fe atoms. The occupancy
rate of the Co atoms at each of the above-mentioned sites exceeded
0.
[0100] Specifically speaking, it means that the crystals of Example
1 are Nd.sub.2Fe.sub.14B crystals belonging to P4.sub.2/mnm and the
Co atoms exist at the 4f site occupied by the B atoms, the second
4f site occupied by the Nd atoms, and the first 8j site occupied by
the Fe atoms, respectively. Accordingly, it was confirmed that some
of the B atoms at the first 4f site, some of the Nd atoms at the
second 4f site, and some of the Fe atoms at the first 8j site were
substituted with the Co atoms. On the other hand, the relevant
occupancy rate of the Co atoms was 0 or less or could not be judged
at the 4g site occupied by the Nd atoms, the 4c site occupied by
the Fe atoms, the first and second 16k sites occupied by the Fe
atoms, the second 8j site occupied by the Fe atoms, and the 4e site
occupied by the Fe atoms, so that it was surmised and recognized
that the atoms existing at those sites were not substituted by the
Co atoms.
[0101] The Rietveld analysis was also conducted for Comparative
Example 1 by the same method as in Example 1. FIG. 10 illustrates
the analysis results of Comparative Example 1 when the fitting
results of R.sub.wp=1.763, R.sub.e=1.729, s=1.0195 were obtained.
Referring to FIG. 10, the occupancy rates of the Co atoms at the
respective sites are: 0.0166 at the 4f site occupied by the B
atoms; 0.0233 at the second 4f site occupied by the Nd atoms; and
0.8405 at the first 8j site occupied by the Fe atoms. The occupancy
rate of the Co atoms at each of the above-mentioned sites exceeded
0.
[0102] Specifically speaking, it means that the crystals of
Comparative Example are Nd.sub.2Fe.sub.14B crystals belonging to
P4.sub.2/mnm and the Co atoms exists at the first 4f site occupied
by the B atoms, the 4f site occupied by the Nd atoms, and the
second 8j site occupied by the Fe atoms, respectively. Accordingly,
it was confirmed in Comparative Example 1 that some of the B atoms
at the first 4f site, some of Nd at the second 4f site, and some of
Fe at the first 8j site were substituted with the Co atoms.
However, when comparing the occupancy rates of the Co atoms at the
4f site occupied by the B atoms between Example 1 and Comparative
Example 1, the occupancy rate of Example 1 is larger. As a result,
it was confirmed that Example 1 in which the carbon content was
reduced had a larger amount of the B atoms substituted by the Co
atoms that that of Comparative Example 1.
[0103] Incidentally, regarding Comparative Example 1, the relevant
occupancy rate of the Co atoms was 0 or less or could not be judged
at the 4g site occupied by Nd, the 4c site occupied by Fe, the
first and second 16k sites occupied by Fe, the second 8j site
occupied by Fe, and the 4e site occupied by Fe, so that it was
surmised and recognized that the atoms existing at the relevant
sites were not substituted by the Co atoms.
Comparative Example 4-1 and Comparative Example 4-2
[0104] Comparative Example 4-1 and Comparative Example 4-2 were
prepared. The raw material alloy with the same charged composition
as that of Example 4 was used for Comparative Example 4-1 and
Comparative Example 4-2. Regarding Comparative Example 4-1, the
heat treatment step was not executed. However, Comparative Example
4-1 was prepared by executing all other steps including the
degassing step and the drying step under the same conditions as
those of Example 4. Regarding Comparative Example 4-2, the
degassing step, the drying step, and the heat treatment step were
not executed. However, Comparative Example 4-2 was prepared by
executing all other steps excluding the above-mentioned steps under
the same conditions as those of Example 4.
[0105] FIG. 11 is diagrams for explaining a manufacturing method of
Comparative Examples of the present disclosure. FIG. 11A and FIG.
11B illustrate transitions of the degree of vacuum and the internal
furnace temperature in the degreasing step and the sintering step
of Comparative Example 4-1 and Comparative Example 4-2. When
comparing FIG. 11A regarding Comparative Example 4-1 and FIG. 11B
regarding Comparative Example 4-2, spike waveforms are observed in
the sintering step in FIG. 11B where the degassing step and the
drying step were not executed. On the other hand, regarding Example
4, the degassing step and the drying step were executed before the
degreasing step, so that no spike waveform appeared in the
sintering step (which is not illustrated in the drawing).
[0106] The rare earth permanent magnet according to this embodiment
has a high magnetic moment and exhibits good magnetic performance.
The rare earth permanent magnet contributes to downsizing, weight
reduction, and cost reduction of electric motors, offshore wind
power generators, industrial motors, and so on.
INDUSTRIAL APPLICABILITY
[0107] The rare earth permanent magnet which exhibits the high
magnetic performance can be provided according to some embodiments
of the present disclosure.
REFERENCE SIGNS LIST
[0108] 100: crystal structure of unit lattice [0109] 101: R--Fe--B
layer [0110] 102: Fe layer [0111] 200: first cycle of Co atoms
[0112] 201: first inflection point in first cycle of Co atoms
[0113] 202: second inflection point in first cycle of Co atoms
[0114] 203: third inflection point in first cycle of Co atoms
(first inflection point in second cycle of Co atoms) [0115] 210:
second cycle of Co atoms [0116] 211: first inflection point in
second cycle of Co atoms [0117] 212: second inflection point in
second cycle of Co atoms [0118] 213: third inflection point in
second cycle of Co atoms [0119] 300: first cycle of Nd atoms [0120]
301: first inflection point in first cycle of Nd atoms [0121] 302:
second inflection point in first cycle of Nd atoms [0122] 303:
third inflection point in first cycle of Nd atoms (first inflection
point in second cycle of Nd atoms) [0123] 310: second cycle of Nd
atoms [0124] 311: first inflection point in second cycle of Nd
atoms [0125] 312: second inflection point in second cycle of Nd
atoms [0126] 313: third inflection point in second cycle of Nd
atoms
* * * * *